Upholstered furniture and method of producing the same



I Dec. 21 1926.

S. KARPEN ET AL UPHOLSTERED FURNITURE AND METHOD OF PRODUC ING THE SAME Filed July 16, 1923 5 s t -s t 1 lllllllllllllllIllllllllfllll-lllll' I five 72). Kama 72% 779672,

Dec. 21 1926. 1,611,751

S. KARPEN ET AL UPHOLSTERED FURNITURE AND METHOD OF PRODUCING THE SAME Filed July 16, 1923 6 s t -s t 2 QSOZO 772073 :Zar vefi,

Dec. 21 1926.

S. KARPEN ET AL UPHOLSTEREU FURNITURE AND METHOD OF PRODUCING THE SAME Filed July 16 1925 6 Sheets-Sheet 5 Dec. 21 1926.

S. KARPEN ET AL UPHOLSTERED FURNITURE AND METHOD OF PRODUCING THE SAME Filed July 16 1923 6 Sheets-sheet 4- Z72 U672 Z070? Dec. 21 1926.

S. KARPEN ET AL UPHOLSTERED FURNI TURE AND METHOD OF PRODUC ING THE SAME Fil y 16, 1925 e Sheets-Sheet I m 111! II I Ill ll/13355125546 71/41 Z I Dec. 21 1926.

S. KARPEN ET AL UPI-IOLSTERED FURNITURE AND METHOD OF PRODUCING THE SAME Filed Jul 16, 1925 6 Sheets-Sheet rzmwzr 'JIIIIIIIIIIIIIIIIII I Patented Dec. 21, 1926.

UNITED STATES 1,611,751 PATENT OFFICE.

SOLOMON KARPEN AND FRANK KASPAR, OF CHICAGO, ILLINOIS, ASSIGNORS' TO S. KARPEN & BROS, OF CHICAGO, ILLINOIS, A CORPORATION OF WEST VIRGINIA.

UPI-IOLSTERED FURNITUIKE AND METHOD OF PRODUCING THE SAME.

Application file'd July 16, 1923. Serial No. 651,790.

This invention relates particularly to the I production of upholstered furniture, such as chairs, sofas, settees, and so forth.

The primary object is to reduce the cost of manufacturing upholstered furniture, without detracting from the appearance and quality'of the upholstered article.

The method of upholstering chairs, sofas, settees, footstools and so forthwhich has been in common use for very many years, requires a high degree of skill, is laborious, and is unnecessarily expensive. For example. according to a known method, a chairfraine is equipped with upholstery springs, mounted, tied and covered in anysuitable manner, as for example in the manner illustrated in the lower structure shown in Fig. 7 of the accompanying drawings. a piece of burlap being placed over the springs and nailed to the frame members; a layer of cotton wadding is then placed on the burlap; a muslin envelope of suitable size is filled with suitable cushioning material, which may comprise springs, hair, cotton or other filling, the cushion thus formed being placed over the cotton layer and the envelope tacked at its edge portions to the frame; hair. cotton or moss or other suitable filling, is placed on top of the cushion referred to and is stitched down .to shape, a cover of muslin beingapplied and the last mentioned filling being suitably shaped within said cover. the edges being squared or rounded off to fit the chair and according to the style. the edges of the muslin being pulled down and tacked to the frame, a finishing cover is then tacked to the frame and drawn snugly over the structure and nailed at its edges to the frame; and a welt is tacked over the edges of the rover to onceal the tacks used in securing the finishing cover: a band of finishing covering, cut to size, is tacked through the welt on to the frame (blind tacked) and this band is pulled down and the edge tacked under the rail of the frame. Should the style of the chair call for an exposed finished wood frame, the finishing cover is tacked in a rabbet, at the upper edge of the rail. and a guimpe is glued or ta ked over the raw edge, thus finishing the job. I

It will be understood by those skilled in the art and in the example given, that the work of building up the seat above the substructure of spring work is not only labori ous, but requires a skilled workman to properly shape the cushion and produce a workmanlike job.

According to the improved method illus- I I ion on the frame of the article of furniture,

and this is accomplished without sacrificing any of the desirable qualities of furniture made 'in accordance with the known methods. Thus, the improved method largely obviates the very laborious portion of producing an upholstered job, renders unnecessary the use of that degree of upholstering skill which is acquired only by years of practice, enables a uniform product to be produced by means of less highly skilled labor, and greatly cheapens the cost of. manufacture.

The invention is illustrated in the accompanying drawings in which- Fig. 1 represents a broken vertical sectional view of a cushion stuffing machine; Fig. 2, a transverse sectional view taken as 'indicated at line 2 ofFig. 1; Fig. 3, a broken vertical sectional view of a chair or a settee constructed in accordance with one species of the invention; Fig. 4, a similar sectional view embodying another species of the invention; Fig. 5, a special perspective View of the envelope employed in the construction shown in Fig. 4: the dotted lines at the right hand portion of the figure illustrating the manner in which the end of the envelope is left open for the stuffing operation; Fig. 6, a special view of an upholstered cushion provided with skirts and rendered to be applied to the frame of a chair or other article of furniture; Fig.7, a broken vertical sectional view of a chair or other article of furniture, showing the skirted finished cushion applied to a frame having a sub-structure or bottom embodying upholstery springs; Fig. 8, a perspective'view of a chair constructed in accordance with the invention. employing the skirted finish cushions for both seat and back; Fig. 9, a broken perspective sectional view illustrating the manner in which the seat-cushion is secured to theframe; Fig. 10. a similar view, showing a modified method of securing the cushishing skirt; and Fig. 12, a broken perspective sectional View showing another modification. illustrating a method of applying the finish cushion to a frame which has an exposed finish-surface.

Referring to Figs. 1, 5 and 6, A represents the envelope or cushion; and B, the filling of the cushion, which comprises, in this case, a spring structure B mounted on a Wooden frame B and a layer of cotton or suit-able wadding B The envelope A has a bottom 1,. which may be formed of canvas or other suitable strong fabric, this bottom being provided at its edges with a depending skirt 1. The envelope has a top 2, which may be of mohair, plush or any other suitable covering material, adapted to serve as a finish covering; the envelope has side portions 2 of the same material, and has the skirt 2", which also is preferably of a finish fabric. In shaping the envelope, welts may be formed, as at 3. and 4, In the illustration given, the welt 3 is shown as formed by folding the side fabric 2 at its upper edge, the welt being then joined to the edges of the top fabric 2 by means of stitches 5; also, the welt 4 isshown as formed at the upper edge of the skirt 2", and the welt thus formed is sewed to the lower edge portion of the side strip 2 and to the upper portion of the inner skirt 1, as by stitches (3.

As shown in Fig. 1, the envelope is preparatorily formed and stitched, but. is left open at one end, and the end flap thrown up.

Also, adjacent the open end, the lateral side strips 2 are left for a short distance unconnected with the bottom fabric 1. That is, in forming the envelope p-reparatorily, one end of the finish fabric is left without being sewed to the bottom fabric and the lower edges of the lateral side strips of the finish fabric are left unsewed to the bottom fabric for a short distance. This enables the envelope to he slipped on to the chute C of the stuffing machine C. The stufiing machine, or cushion forming machine, may be of any suitable construction. Such machines are known, and need not be described in detail herein. The machine is provided with a longitudinal passage or way C in which the stuffing or cushion material B is placed. The passage C has a top wall C, which may be raised to enable the cushioning material to be introduced. Also, the chute C tapers longitudinally, and comprises two telescopic U-shaped sect-ions 7 and 8, as shown in Fig. 2, The upper section 7 is secured to the member C and the lower section 8 is bolted, as at 9. to the main frame 10. A follower C, actuated by an endless chain C in a well knownmanner, serves to expel the cushioning structure B from the Way and force it through the tapered chute G into the envelope of the cushion, itbeing understood that an attendant holds the envelope in position during springs are tied by cords 11 in the usual' manner; and a burlap cover 11 is placed over the springs and tasked to the frame. Thus, the wadding, such as cotton batting or the like, 13", may be placed upon the spring structure without danger of working into the springs. The spring structure may be provided with a spring edge 11, as shown in Fig. 6.

The finished cushion, constructed as illustrated in Fig. 6, may be applied, for example, to the seat frame D of a chair I), as shown in Fig. at. In this figure, the finished cushion is of the same construction as that illustrated in Fig. 6, except that the form of the wooden frame B is slightly modified, and is here designated 13, The other parts of the cushion are the same as shown in Fig. 6, and are designated by the same reference characters. Still referring to Fig. 4, the finished cushion is placed in position in the chair with the wooden frame B" resting on the seat frame I); the short inner skir 1 is drawn down over the upper portion of the outer surface of the seat frame D and is secured to the seat frame by tacks 12, The outer, or finish fabric skirt 2" is drawn down to cover the outer surfaces of the rails of the seat frame and is secured to the lower edges of the rails by tacks 13. \Vhere desired, cotton batting or other suitable stufling material 14 is introduced between the skirt portion 2 and the rail of the seat frame of the chair.

Referring to Fig. 3, E represents the frame of a chair or other article of furniture, and E represents the seat frame which forms a part of the structure.

F represents a finished cushion which is formed in the manner described with reference to the cushion shown in connection with 'the article of furniture depicted in Fig. 4.

except that the skirts are omitted from the finished cushion. In Fig, 3, the article of furniture is designed to have the outer surfaces of the rails of the seat frame E present finished wood surfaces. The seat frame is therefore formed as a socket to receive and house the lower portion of the cushion structure. The cushion is shown as co1nprising an envelope having top 15, and side strips 15 made of finish fabric and having a bottom 15 of canvas or other suitable strong, comparatively cheap fabric. The lower edges of the side strips 15 are sewed to the edge portions of the bottom 15, as indicated at 15 The cushioning structure which is enclosed within the envelope 15 comprises a wooden frame 16, equipped with a suitable rod or wire foundation, 16; upholstery springs 16 supported on the foundation, cords 16 securing the springs in position; a. burlap cover 16 over the springs and secured to the inner frame 16; and a layer of cotton or other suitable wadding material 16 over the burlap. The stuffing operation is effected in the manner already described with reference to the cushion structure shown in Figs. 4 and 6. All that is necessary to effect the upholstering of the chair, after preparing the cushion, is to insert the cushion in the frame, the lower portion of the cushion structure being supported on and housed within the seat frame E. This seat frame is shown as comprising the exposed rails 17 and inner corner braces 17 which are rigidly secured to the lower portion of the rails. The inner frame 16 rests upon the corner braces 17 and is secured thereto by means of screws 18. Thus, the proper upholstering of an article of furniture of this design is effected by simply inserting the finished cushion in the socket provided by the seat frame and attaching the inner frame with which the cushion is provided to the seat frame by means of screws, or the'like,

Referring to Fig. 7 G represents the frame of a chair or other article of furniture which is provided with a seat frame G, a spring structure G built within said seat :rame, a back G and arms G; and, in addi tion, a finished seat-cushion H and a finished back cushion H, preparatorily constructed, and applied to the frame of the article of furniture.

The cushionlil is, in this instance. shown as comprising a fabric casing or envelope 19, and cushioning material with which the envelope is stuffed. The seat frame of the article of furniture is sprung, or provided with a spring structure G according to well known practice, and need not be described in detail. It affords a deep spring structure which is surmounted by a seatcushion H. The envelope 19 comprises the canvas bottom member 19 and top member 19*. side strips 19, andouter skirts 19 of finish fabric. The canvas 19 has its marginal portions'affording a relatively short skirt 19". which is secured to the upper portion of the seat frame G by means of tacks 21. The outer skirts are secured to the lower edge of the seat frame by tacks 22. The stuffing 20 comprises layers of cotton batting or other suitable filling material 20 and 20 and a spring structure 20 which, may be a spring structure of the Marshall type, that is, a fabric envelope provided with individual pockets containing coil springs, as is Well understood in the art. In the construction here being described, it will be noted that the inner skirt 19 has its back flap extended and tacked beneath the rear rail of the seat frame, while the back flap of the outer skirt is omitted. This expedient may beemployed where it is not important to use finish fabric at the rear of the article of furniture, Still referring to Fig. 7, the back cushion H is formed independently, and then ap plied to. the back frame G In this case, a suflicient foundation is provided on the back frame by tacking a strong sheet of fabric 23, such as canvas or burlap to the front surfaces of the rails comprising the back frame. The cushion H comprises an envelope 24 and stuffing 24 which may consist of springs and suitable wadding, such as cotton batting, hair ormoss. The envelope 24 is formed with flaps or skirts 2 which are drawn over the frame and tacked thereto. At the sides and top of the back frame. the skirt flaps may have their margins tacked to the back surface of the frame member, as by means of tacks 25. be tacked to the underside of the lower cross member of the back frame G by tacks 26.

Thus it will be understood that the structure shown in'Fig. 7 is made to present a finished upholstered appearance and to possess the durability and luxurious qualities of an article of furniture upholstered in the ordinay way by the simple expedient of providing previously stuffed cushions and applying them, in the manner described. Indeed, an article of improved appearance and uniformity can be provided by means of the improved method and without the use of highly skilled labor, inasmuch as the proper proportioning, shaping and balancing of the upholstering materials is provided for by employing correct patterns for the cushion envelopes, and effecting the stufling of the envelopes by a labor-saving machine. Referring to Figs. 8 and 9, I represents a The lower flap may chair having a seat-cushion I and a back cushion T applied thereto by means of the improved method. In this case, the seat frame 27 has built therein, in the usual manner, a spring structure 27", which is covered with burlap 27 The seat-cushion T has'an envelope 28 comprising a canvas base 28", which affords an inner skirt 28 and the seat-cushion has its top 28, its side strips 28. and its skirts 28 formed of finish fabric. The stufling of the seat-cushion is designated 29 and is composed of springs and other suitable stuffing material in the same manner as the seat-cushion H shown in Fig. 7. The inner, short skirt 28 is secured to the outer surfaces of the seat by tacks 30, and the outer skirt has its lower margin secured by tacks 31 to the lower edges of the members of the seat frame. Wedding 32 is interposed between the skirt 28 and the members of the seat frame. The back cushion I may be formed and ipplied in the same manner as the cushion shown in Fig. 7. It will benoted that the chair shown in Fig. 8 is provided with arms 33, whose front ends are supported on rounds 33, secured to the sides of the seat frame. The arms are suitably covered, as indicated in the drawing; and the seat-cushion I and back cushion I are recessed, as indicated at 34 and 35 to accommodate, respectively, the rounds 33 and the rear end of the arms 33.

The construction shown in Fig. 10 is similar to the construction shown in Fig. 9, except that the outer skirt 28 is not attached by lines of stitching. In this case, the side strip 28 is provided with an extension 28 and a tackingstrip 36 and tacks 36 are employed to secure a down-turned margin 28 of the skirt 28, the extension 28 and the inner skirt 28 to the seat frame 2?. The lower margin of the outer skirt 28 is tacked to the lower edge of the seat frame in the manner illustrated in Fig. 9.

Referring to Fig. 11', the figure shows a modified method of applying the outer skirt to the cushion. In this figure, J represents a frame of an article of furniture, such as the seat frame which is sprung or equipped with a spring structure J built thereln in the usual manner, the spring structure having in this case a spring edge or marginal rod J disposed some distance above the frame member J. The cushion K is formed independently, as has been described with reference to the other structures. In this case, the cushion has an envelope comprising a canvas base 37, whose margin affords an inner skirt 37; and the cushion envelope has the top member 38 and the side strips 38 of finish fabric. The outer skirt 38" and welt 38 are formed of finish fabric'and the welt portion is connected with the previously applied cushion and with the marginal rod J 2 of the spring structure by means of a lacing, or heavy thread 39. The inner skirt 37 is secured to the frame J by tacks 40, and the lower margin of the outer skirt-38 is secured to the lower edge of the frame member J by means of tacks '(not shown) in the same manner as the skirt 28 is secured in Fig. 9.

Referring to Fig. 12, L re resents a frame, such as a seat frame, an M represents a preparatorily formed cushion. The frame L has, in this case, an outer finish surface 41. and a rabbet 41 at the, upper portion. The cushion M comprises an envelope having a base fabric 42, a top fabric 42 an inner side flap 42 which may be of canvas, and an outer side fabric 42 of finish fabric The members 42 and 42 are extended to provide rudimentary skirts 42. These rudimentary skirts are secured in the rabbet 41 by means of tacks 43, and these tacks and the margins of the skirts are concealed by a guimpe 44 which may be glued in position, or secured by finish tacks 45. The cushion M is formed by stuffing a frame supported spring structure 46 and wadding 46? in the envelope described. The cushion is then applied to the frame in the manner described. This is another instance'of applying a preparatorily formed cushion to a frame which is provided with a finish outer surface, rudimentary skirts being preferably employed in this case in connection with a rabbet to receive the skirts and the finishing guimpe. This may be compared with the construction shown in Fig. 3, where the lower portion of the cushion structure is simply received in a socket formed by the seat frame of the article of furniture, the inner frame being secured to the seatframe by screws or the like. In the construction shown in Fig. 12, the cushion is secured by the rudimentary skirts and tacks. These skirts maybe very short, or may even be omitted in aconstruction of thecharacter shown in Fig. 12, in which case the lower cornersof the envelope of the cushion would be stretched down into the rabbet and tacked therein, and the concealing guimpe then applied.

It will be noted that in all of the constructions described, previously stuffed cushions are employed, and provision is made for so applying the cushions to the frame of the article of furniture as to secure the effect of an upholstering job performed according to known methods. That is, all of the durable and luxurious qualities of the old method of upholstery are retained in the practice of the new method, but by the new method greater uniformity is secured, the use of highly skilled labor is rendered unnecessary, and the expense of producing a properly upholstered article is greatly reduced.

The foregoing detailed description has been given for clearness of understanding only, andno unnecessary limitations should be understood therefrom, but the appended claims should be construed as broadly as permissible in view of the prior art.

Vhat we regard as new, and desire to secure by Letters Patent, is:

1. An article of furniture comprising a frameand a separately formed cushion secured in said frame, said cushion comprising a permanently closed envelope having an upper side. and edge portions of finish fabric and cushioning means completely en- I means including a spring structure carried by a wooden frame mounted on said firstnained frame to form therewith an upholstered article of "furniture, the fabric of said envelope extending between said main frame and the frame of said spring structure.

2. An article of furniture comprising a seat frame provided at the upper portion of its outersur-faee with a rabbet, a separately formed cushion comprising an envelope whose upper side and edge portions comprise a finish fabric, said envelope being provided with rudimentary skirts at its lower corners, and cushioning means stuffed within said envelope comprising a supporting frame and a spring structure mounted thereon, said cushion being mounted with the frame of said spring structure supported on the seat frame and said rudimentary skirts being tacked in said rabbet, the fabric of said enevlope extending between the seat frame and the frame of the cushion structure; and a finishing guimpe concealing the tacking of said skirts.

SOLOMON KARPEN. 5 FRANK KASPAR. 

